Slurry forming process using an inflatable/collapsible bag within a mixing device

Abstract

A method for the production of slurries which are uniform in density and consistency. In particular, a method for preparing zinc anode slurries employed in producing anodes for alkaline batteries. The method comprises a bag slurry forming process, using a drum mixer, involving mixing dry anode components within a sealed, inplated, gas-tight, liquid impervious, flexible, collapsible bag; and, then adding a wet component to the bag, collapsing said bag, and tumbling-kneading the components to form a blended slurry.

What is claimed is: 
     
       1. A method of forming a slurry of selected dry and wet component comprising: introducing selected dry slurry components into a flexible, collapsible bag;   inflating and sealing said bag to confine said components therein;   agitating the sealed bag within a mixing device,   so as to blend the confined components;   opening said bag and introducing a wet slurry component into said bag;   collapsing said bag and resealing the bag to confine the wet and dry components therein; and,   operating the mixing device to knead and blend the confined components into a slurry composition.   
     
     
       2. The method of claim 1 wherein said mixing device is a rotating drum mixer. 
     
     
       3. A method of forming a slurry of select dry and wet components comprising: introducing the dry and wet components into a flexible, collapsible bag;   collapsing said bag and sealing the bag to confine the components therein;   placing the collapsed bag within a mixing device; and,   activating said mixing device to agitate said bag, so as to knead and blend the confined components into a slurry composition.   
     
     
       4. The method of claim 3 wherein said bag is a gas-tight, liquid-impervious bag. 
     
     
       5. The method of claim 3 wherein said mixing device is a rotating drum mixer. 
     
     
       6. A method of forming a slurry in a rotating drum mixer comprising: introducing dry slurry components into a flexible, collapsible bag;   placing said bag within a rotatable drum of the drum mixer;   inflating said bag and sealing the bag to confine the components therein;   rotating the drum to mix the dry components;   opening said bag and introducing a wet slurry component into said bag;   collapsing said bag and sealing the bag to confine the wet and dry components therein; and,   rotating the drum to agitate and tumble said bag, so as to knead and blend the confined components into a slurry composition.   
     
     
       7. The method of claim 6 wherein said bag is a gas-tight, liquid-impervious bag. 
     
     
       8. The method of claim 6 wherein said bag is inflated with air to conform said bag to the shape of the drum interior surface before it is sealed and the drum is rotated to mix the confined components. 
     
     
       9. The method of claim 6 wherein, after introducing a wet slurry component into the bag, said bag is flushed with oxygen before said bag is collapsed and the drum is rotated to blend the confined wet and dry components into a slurry. 
     
     
       10. The method of claim 6 wherein the dry and wet components blended to form a slurry composition are dry and wet anode components. 
     
     
       11. The method of claim 10 wherein dry anode components comprising zinc powder, a gellant, and a fluxing agent are first mixed in the bag; and a wet slurry component comprising an electrolyte solution then is introduced into said bag and the confined components are kneaded and blended to form a battery anode slurry composition. 
     
     
       12. The method of claim 6 comprising: after rotating the drum to mix the dry components therein, opening said bag and introducing at least one additional dry component into the bag;   sealing the bag to confine the components therein; and,   rotating the drum to mix the confined dry components.   
     
     
       13. The method of claim 12 comprising: introducing dry slurry components comprising zinc powder and fluxing agent into said bag;   inflating said bag;   rotating the drum to mix the zinc powder and fluxing agent;   opening said bag and introducing at least one additional dry component comprising a gellant into said bag;   sealing the bag to confine the components therein;   rotating the drum to mix the confined components;   opening said bag and introducing a wet slurry component comprising an electrolyte solution into said bag;   collapsing said bag; and,   rotating the drum to knead and blend the components into a slurry composition.